Process Engineer
AmeriLux · De Pere
Join the A-Team as a Process Engineer! The Process Engineer is responsible for supporting, optimizing, and maintaining manufacturing processes within a continuous plastic extrusion facility. You will work closely with production, maintenance, quality, materials management, and operations leadership to ensure equipment operates efficiently, products meet quality standards, and production goals are achieved safely and consistently.
This position combines hands-on machine operation and troubleshooting with processes, production planning, inventory management, system administration, employee training, and continuous improvement. The ideal candidate is mechanically inclined, detail-oriented, and comfortable working on the production floor in a fast-paced manufacturing environment.
Job Duties | Qualifications:
Process Engineering & Equipment Optimization
- Operate and monitor plastic extrusion machines and related production equipment to support manufacturing operations.
- Develop, evaluate, and optimize extrusion processes to improve productivity, product consistency, material utilization, and overall equipment efficiency.
- Troubleshoot process, equipment, and product issues, identifying root causes and implementing corrective actions.
- Assist with machine setup, changeovers, startup procedures, shutdowns, and process adjustments.
- Build, assemble, modify, and maintain extrusion dies and related tooling as required.
- Calibrate equipment and verify that machine settings and process parameters meet established specifications.
- Develop, update, and maintain machine specifications, setup sheets, operating parameters, and standard work instructions.
- Monitor critical process variables, including temperatures, pressures, line speeds, cooling conditions, and material feed rates, as applicable to the equipment.
- Support new product introductions, process trials, tooling changes, and equipment improvements.
- Collaborate with maintenance personnel to identify equipment issues, reduce downtime, and improve equipment reliability.
- Document process changes, trial results, downtime, and corrective actions to support repeatable manufacturing performance.
Production Planning & Scheduling
- Participate in production scheduling and resource planning for production operators and manufacturing equipment.
- Coordinate production priorities with operations leadership to meet customer demand and delivery commitments.
- Help ensure the availability of raw materials, tooling, equipment, and labor needed to execute the production schedule.
- Monitor production performance against established schedules and identify potential bottlenecks or delays.
- Communicate production constraints, material shortages, equipment issues, and scheduling conflicts to the appropriate team members.
- Assist with balancing workloads and improving production flow across manufacturing operations.
Quality Assurance & Continuous Improvement
- Monitor manufacturing processes to ensure products meet established specifications, quality standards, and customer requirements.
- Assist with investigating product defects, process deviations, scrap, and rework.
- Collaborate with the quality team to identify root causes and implement corrective and preventive actions.
- Collect and analyze production data to identify trends, inefficiencies, and opportunities for improvement.
- Participate in continuous improvement initiatives focused on reducing scrap, minimizing downtime, increasing throughput, and improving labor and material efficiency.
- Support the development and implementation of standard operating procedures and best practices.
- Monitor metrics including production output, scrap rates, downtime, and overall equipment effectiveness, where applicable.
- Promote consistent manufacturing practices and repeatable processes across shifts.
ERP Systems & Production Documentation
- Work within company management systems, including NetSuite and Microsoft Dynamics 365.
- Audit and accurately enter production, material usage, and inventory data into NetSuite.
- Create and maintain sales orders and work orders in Microsoft Dynamics 365, as assigned.
- Verify the accuracy and completeness of system transactions, production records, and material movements.
- Reconcile discrepancies between physical inventory, production activity, and system records.
- Maintain accurate documentation related to machine settings, production runs, material consumption, quality issues, and process changes.
- Identify opportunities to improve data accuracy, system utilization, and the efficiency of production reporting.
Material & Inventory Management
- Monitor raw material, work-in-process, finished goods, and production supply inventory levels.
- Identify and communicate material shortages, inventory discrepancies, and potential production interruptions.
- Perform cycle counts and reconcile physical counts against ERP system records.
- Receive, stage, organize, and move materials to support production requirements.
- Participate in the development and implementation of effective raw material storage and organization solutions.
- Help establish appropriate material handling, identification, traceability, and storage practices.
- Coordinate with purchasing, warehouse, and production personnel to ensure materials are available when needed.
- Support inventory accuracy initiatives and help minimize material waste, damage, and unnecessary movement.
Training & Employee Development
- Participate in onboarding and training new hires on equipment operation, production procedures, system transactions, and standard work.
- Assist in developing and maintaining work instructions, training materials, and equipment-specific documentation.
- Provide hands-on guidance to operators regarding machine setups, process parameters, troubleshooting, and quality expectations.
- Reinforce consistent operating practices and encourage adherence to established production standards.
- Support cross-training initiatives to improve workforce flexibility and departmental efficiency.
Safety & Compliance
- Follow all established safety policies, standard operating procedures, and safe work practices.
- Perform all duties with a strong commitment to employee safety, product quality, and operational excellence.
- Identify and report unsafe conditions, equipment hazards, and potential process risks.
- Follow applicable lockout/tagout procedures and other required safety protocols when performing authorized tasks.
Customer & Cross-Functional Support
- Serve as a professional, customer-facing representative when interacting with customers in warehouse, shipping, and loading environments.
- Communicate professionally with internal departments, vendors, and customers as required.
- Collaborate with operations, maintenance, quality, warehouse, purchasing, and customer service teams to resolve production and material-related issues.
- Support special projects and other operational initiatives as assigned.
Requirements
Experience in a manufacturing, industrial, production, or process-oriented environment.
Mechanical aptitude and the ability to operate, troubleshoot, and adjust manufacturing equipment.
Strong attention to detail and the ability to maintain accurate production, inventory, and system records.
Basic computer proficiency and the ability to learn and navigate ERP and manufacturing management systems.
Strong problem-solving, organizational, and communication skills.
Ability to work collaboratively across departments and communicate effectively with employees at all levels.
Commitment to workplace safety, quality standards, and established operating procedures.
Ability to manage multiple priorities in a fast-paced, continuous manufacturing environment.
Benefits
Award winning zero-dollar deductible healthcare plan with yearly physical reimbursement
Comprehensive vision, and dental plan
Free onsite health clinic, ER services and Telehealth services
Retirement plan and a company match
Free onsite gym, pickleball, and basketball court
Free monthly company lunches
Front-loaded PTO
Advancement opportunities
On going training and tuition reimbursement
Yearly bonus up to 4% of earned wages
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